Tailoring of versatile surface morphologies on hot dip galvanized steel in wet CO2: aspects on formation, barrier properties, and utilization as a substrate for coatings

Zinc carbonate and a mixed-phase zinc carbonate were precipitated selectively on hot dip galvanized steel in the presence of CO2 and water. The zinc carbonate was precipitated as a uniform layer with cubic superficial appearance, while the mixed-phase zinc carbonate was precipitated as nanowires. The distinct structures could be formed separately or as a dual structure with nanowires on the outermost surface. The barrier properties were improved by the both patina forms; a significant increase in surface hydrophobicity was obtained. The dual patina structure was successfully coated with an organic coating, and the intact wet CO2-induced patina with both structures was confirmed within the coating. The formed carbonates can be further converted to zinc oxide by calcination, preserving the delicate structures, which opens a wide range of potential applications for the nanostructured ZnO in a variety of future electronic and optoelectronic devices.